Pbocess of and means fob flaking soap



July 26, 1932. a w. CQLTMAN Re. 18,546

PROCESS OF AND MEANS FOR FLAKING SUAP I VOriginal Filed Aug. 15, 1921 2 Sheets-Sheet 1 July 26,1932. B. w. COLTMAN Re.1s,546

PROCESS OF AND MEANS FOR FLAKING SOAP Original Filed Aug. 15, 1921 2 Sheets-Sheet 2 Reissued Jly 26, 1932 `UNITED STATES Re'.A` 18,546

PATE-NT- OFFICE IBERTRAM'W. COLTMAN, OE CHICAGO, ILLINOIS PROCESS F AND MEANS FOR FLAKING- SOAP 'Original No. 1,653,390, dated December 20, 1927, Serial No. 492,214, led August 15, 1921. Application for reissue filed August 22, 1929. Serial No. 387,752.l

My invention relates to the process of and means for llaking soap.

The invention is particularly concerned with producing llaked soap for use '1n the I laundries, or in general by the housewife, al-

though the theory involved may be advantageously employed as an intermediate step in the manufacture of cake or bar soap, Where it is necessary to convert the liquid soapinto l0 chips in order to obtainy the proper homogeneity when formed into bars or cakes.

The reason for the inability to manufacture a\high grade of Asoap in flaked condition at a reasonably low cost has been due chiefly to the necessity of needless repetitionV of several steps in the process. Heretofore,

llaked soap has .been merely 'the cake soap A out up again into shreds in order to place it in a condition more suitable for use. I 'his 2 has resulted in increased cost in production. Iureality, this soap is not flaked, but shaved,

which of. course must necessarily be of great,

er thickness. x

From actual experience it has been found I 25. that shaved soap must be instantly soluble in the Washing fluid, and as a requisite thereto, the shavings must be light and verythin, but such as will prevent massing or pasting to ether while in packages. 3 fla s are used Where a saving in time an mass before being used, dueto moisture, heat, 0r lack of thorough desiccation, the advantage ordinarily obtained by their use will.

' 85 be1ost.

Practically all soap is iiaked while in some stage of its'making. This is particularly true.

'J secondlaminating roller, and so on, untilit ispressed int-o a thin sheet for shredding or chipping. I The shredsiare placed upon drying-aprons, andv a delivery apron is pro-l Usually vsoa produced' is again shredded. These shreds' usually are not of a fine texture, being too coarse to permit instant solubility.

According to the present invention, a thin flake is produced, being practically transparent and in a state nezit to powder. With the flakes in this condition, the field for the use oflaked soap is greatly extended. The flakes are in a perfect condition to-obtain the desired solubility in the vwashing fluid.

Briefly. the theory involved includes sprayn ing liquid soap in fine cloudsupon a traveling apron, which results in the formation of a fine sheet of soap. This sheet of soap is then carried by the aprons through an evaporating. zone, such as a hot or cold air blower directing currents against the apron, or such as a warm air oven or chamber housing a portion of the apron. The soap is thoroughly desicc'ated and is in a frozen or inlabor is desired, and hence, lf'thel flakes the apron, so that it breaks up in fine flakes as the apron travels around the endy roller. I propose employing various means for removing thesoap fromthe apron, and even contemplating resorting to various forms of aprons, which will function to remove the soap when reaching'a-certain`point.

.I have found by reducing the density of the liquidV soap before feeding it through the sprayers onto the apron, that the flakes will be light and porous, which of course permits greater solubility. This desired result is secured by first mixing the liquid soap,as it comes from the cooking vat, with a'thinning fluidI which reduces its consistency, so that it may be worked with greater facility when aerat'e'd by Whipping or blowing air through, or other suitable process, so as to convert it into a' mass whose weight is considerably less than that of the same volume of ordinary liquid soap. After aerated, the Vsoap will be frothy and 4very light and maybe sprayed' with greater facility upon the apron. While a thinning fluid has been found desirable, its use is not essential to the aerating step, as liquid soap of any consistency may be whipped to increase its volume.

In the drawings; Figure 1 is alayout of apparatus for producing a flake embodying my invention;

i Figure 2 is an alternative lay out of apparatus embodying my invention;

Figure 3 illustrates a form similar to'Fig-u ure 2; but showing the use of a hot air voven and cooling chamber.; and

Figure/l illustrates an alternative means for removing the soap from thepapron after it is desiccated.A l

Referring to the illustration in Figure 1, liquid soap is fed into the vat 2 through the.

supply pipe-3 containing the supply control valve 4. The supply pipe 3 may lead directly from the large vat wherein the necessary constituents are thoroughly mixed and prepared into soap. The solution taken from such a vat may contain about 25% moisture;r This, of course, may be varied. In the vat 2, the volume of liquid soap is increased `by being mixed with water or other suitable fluid, such as alcohol or acetone, which reduces its density to permit freer flow, besides being thinned out considerably. The thinning fluid is fed into the vat 2 through the valve 5 and pipe 6. This fluid is mixed with the soapy solution by means of an ordinary wire stirrer 7 usually employed where a mixing action is preferable over an ebulliting or kneading action.- The stirrer 7 is carried 'upon a shaft 8 which is driven by any suitable means, as for instance by a belt 9. A hot air jacket 1() surrounds the mixing vat 2 to keep the contents thereof at a certain temperature.

From the vat 2 the liquid soap of reduced consistency is fed through the valve 11 into the whipping vat 12, which, as shown, is of the ordinary type. The whipper comprises simply the belt driven shaft -13 carrying wires'or rods 14, which stir and aerate the material. The constructionlis such that the stirring instrumentalities, i. e., wires or rods, pass through the viscid mass-with a smoothcutting, as again distinguished from either.

an ebulliting, or kneading action, whereby there is oli-tained indefinitely repeated' cutting of the occluded air into smaller and smaller subdivisions with comparatively small levitation or expulsion thereof, or conversion of the mass throughout into4 froth or foam.. In this machine, the yliquid soap is brought into a foan'iing mass. aerating step, the liquid soap is kept at a cery tain temperature, which greatly 'facilitates the movement thereof, the heat being sup- During thel plied by a warm air jacket 23 surrounding the vat 12.-

Therefrom it passes or preferably is sucked through a pipe 14 by a pump 15, and

sprayed in the form of a mist upon the traveling surface 16, forming athin film or y thereover by its own action. As the belt' travels along its upper horizontal run, Warm air of sullicient avidity to remove the moisture `is directed against the soap by means of 'the blower 18 and manifold 19 having any number of jets 20 from which the air is emitted. By the time the soap reaches the end of the belts horizontal run, it will be of a spon'gy and frable nature, that is, there will be a te'ndency-v for it to crumble into fine flakes as soon as it is disturbed. It is here proposed to provide such disturbance by creating an abrupt break in the straight run of the belt. The comparatively small diameter roller 21 serves this purpose, while, if so desired, an auxiliary means may be used to remove soap which persists in clinging to the belt. This auxiliay means is in the form of one or more blades '22, which lightly bear against the belt without Wearing or destroying the same. It is to be'noted that the flakes are permitted to drop practically untouched into the receptacle 23, which prevents lumpof this particular process willpproduce a ing. It is further to be noted that the use break or crumble into bits when disturbed;

the flake having' a great avidity tov dissolve instantly upon mixing with a washing fluid.

An alternativellprocess for flaking soap is shown in Figurej.i In this instance, the liquid soap is taken from'the cookingvat (not shown) with a consistency of about 25% moisture, and fed through the supply pipe 25,

the flow being controlled by the valve 26, to the vat 27. The liquid soap, while in this vat 27, is kept at a certain temperature to prevent cooling 'f which is apt to result in crust-ing, but this hasbeen found not necessary. With the soap in such stateit is advisable to employ a pump 28, preferably of the' ordinary centrifugal type, to draw the soap from the vat 27 and force-it through the sprayer 29,

which divides the flow,'so that the soap is discharged inl a comparatively fine mist,

`whiehsettles upon the traveling surface 30 1n a thin sheet. This sheet of Soap is advanced under the streams of warm air emitted from 4the iets 20 of the manifold19. The length of the belts horizontal run is such as will permit a manifoldl of sufficient capacity to be used to dcsiecate the soap lilm, and also permit adequate cooling of the soap film before it is disturbed and crumbled into flakes.

By referring to Figure 3, an alternate suggestion for desiccating the soap film upon the traveling surface will be' seen. It is considercd a matter of ordinary mechanical skill to propose a different method for desiccatino' the soap upon the surface 30, as the scope o the present invention should extend to any method of desiccation. Theparticular construction shown in Figure 3 comprises a warm air oven 33 through which the surface \is led. Freely rotating rollers 35 may be mounted Within this Warm air oven 33 and adjusted so as to engage lightly the pellicle of soap on the belt. This will, moreor less, roll out the pellicle soap in a positive fashion, the purpose being primarily to remove the gloss and to prevent crusting of the surface, Which causes uneven drying.

From experience it has been foundA that soap flakes will remain in a very much better condition if thoroughly cooled before placing in packages; while oftentimes a finer quality of flake is obtained by removing the heat before it is crumbled. A cool air chamber 34 is provided for this purpose and is preferably disposed adjacent to the warm air oven 33, at the end of the belts travel.

In the forms thus .far described, a scraper knife is employed to assist in removing the flake from the traveling surface. Should this, not be preferred, other means may be employed, such as for instance lowering the end roller 21 slightly and using a freely rotatable roller 37 to maintain a greater portion of the belt run horizontal. The belt between the roller 37 and roller 21 will slant slightly downwardly, with the roller 38 having an irregular periphery to provide tlie necessary vibrations, to loosen and crumble the soap, interposed therebetween. Thus, no element comes into contact with the soap, after it has been desiccated, to crumbled it.

-Without further elaboration, the foregoing willv so fully explain the gist of my invention, that others may,'by applying current knowledge, readily adapt the same for use under varying conditions of service. The invention is not to be limited to aerating to cause frothing of the liquid soap before it is spread upon produce a flake which is very desirable, being' the belt. The invention will, however A spongy, friable, and of a very soluble character. The feature of sprayinga thin film of soapy solution upon a traveling (horizontal) surface, against which is directed currents of Warm air, and then disturbing the desiccated soap by changing the direction of travel of the surface, is considered of importance. However, the general mode of operation may obviously be changed without eliminating important parts, which may properly be said to `constitute the essential features of novelty involved in my invention.

The invention aims to-produce a soap Hake of higher quality. over what has heretofore been made. ygested, the nature of which is such that To this end, a process is sugvarious steps may be omitted without deviating from theinvention with respect to changing the nature 4of flake produced, as is contemplated within the limits of the ,present case. Of thel steps that may be omitted or interchanged, that of aerating to increase the volume per unit of weight is mentioned. Variation of this latter step is possible Within a wide range, and hence, it is the increased volume which is sought. Laying the liquid soap on the belt by a'sprayer may b e omitted when the aerating or other volume increasing means are employed.

I claim: t

l. The method of flaking soap which comprises first spraying it while in liquid form into a thin film, next, operating upon the film to cause desiccation, and finally, disturbing the desiccated film to cause disintegration into flakes.

2. The method of flaking soap which comprises first laying a layer of liquid soap upon a surface, next, conditioning said soap while` lng surface, next, passing said surface v Y through a desiccation zone to remove the moisture in the soap, and finally, removing he soap in flaked condition from said surace.

4. The method of fiaking soa-p which comprises first spraying a thin film of liquid soap upon a traveling surface, next, passing said surface through a hot air zone to remove the moisture contamed 1n the soap,l next,

`changing the travel of said surface to cause breaking up of said soap, and finally, scraping said surface to remove whatever soap that remains thereon.

5. The method of flaking` soap which comprises, first spraying a thin film of liquid soap upon a traveling surface, next, passing said surface through a hot air zone to re`- move the moisture contained in the soap, next, passing said surface through a cooling Zone to lower the temperature of the desiccated soap, and finally, changing the travel of said surface to cause breaking up of said soap.

6. -The method of flaking soap which comprises first spraying a thin film of liquid soap upon a traveling surface, next, passing said surface through a. hot air zone to remove the moisture contained in the soap, andnext, passing said surface vthrough a cooling zone to lower the temperature of the/desiccated soap before removing soap from said surface y and finally removing the desiccated soap in the form of Hakes.

7. The method of Haking soap which comprises irst reducing the density of a body 5 of liquid soap so that it will be of a desired consistency, next, converting the body of'liquid soap into an aerated and foamy mass, next, shaping said mass into a film of desired thickness, next, drying said sheet, and finally,

1 producing Hakes therefrom.

8. In the method of Haking soap which comprises Hrstconverting a body of 'liquid soap into a frothy or foamy mass, next, laying said mass upon a surface in form of a substantially thin sheet, and finally, drying said sheet so as to render the same friable and crumbly, whereby to divide said sheet into flakes.

9. In the method of flaking soap which comprises first mixing a thinning Huid with a body of liquid soap, next, whipping said body of liquid soap into a froth, next, desiccating to any desired degree, the frothed soap to renderit friable, and finally Haking the soap. l

10. In the method of flaking soap which comprises first mixing a thinning Huid with a body of liquid soap, fnext, frothing said body of liquid soap by whipping and admit- 3 ting air thereinto, next, placing the soap upon an exposed surface, next, passing said surface through a desiccating zone to dry said soap, and finally Haking the soap.

11. In the method of Haking soap which comprises first mixing a thinning Huid with a body. of liquid soap, next, admitting` air into said body of liquid soap by whipping, next, placing the aerated liquid soap upon a traveling surface, next, desiccating said 4, aerated liquid soap, and finally, removing the aerated soap in form of crumbled Hakes by disturbing said travelingqsurface.

12. In the method of Haking soap which comprises first aerating by whipping a body 5 of liquid soap, next spraying the aerated liquid soap upon a traveling surface, next, desiceating said aerated soap, and finally, removing the aerated soap in form of crumbled Hakes by disturbing' said traveling surface.

5 13. In combination, a source of liquid soap,

a vat for receiving said liquid soap, an apron,

means for removing said liquid soap from lsaid vat to place it upon said apron in a thin sheet, means for directing currents of air of sufficient avidity to remove moisture from said sheet of soap, and means substantially at the end of said apron to upible and remove said soap.` r

14. In combination, a source of liquid soap,

`. 50 a traveling apron', means for placing said soap upon said apron in form of a thin sheet, means for desiccating saidvsheet of soap while Ion said apron, the direction of travel of said apron being changed 'to crumble said soap into Hakes, and additional means for assistture or hardening the soap whereupon the air .substantially at uits end to crumble the soap into Hakes.

16. In combination, a sourceof liquid soap, means for converting the liquid soap into a froth, a sprayer for spraying said froth upon an apron, a desiccating zone for rendering said froth in a friable condition, and means for disturbing the friably conditioned froth' so as to remove it" from theapron in form of Hakes. l i

17. In combination, a source of liquid soap, a converter for converting said liquid soap into a froth, a sprayer for spraying the froth upon an apron, a Warm air zone for removing moisture from said froth, a cool air zone for removing. heat from said froth, and means at the end of the apron to disturb said froth.

18. The method of producing soap flakes having a high degree of porosity and easily soluble in Water which comprises spraying liquid soap of a high air content upon a moving surface, and then removing the mois- 05 is `allowed to escape andthe soap rendered friable and finally disintegrating the samey into flakes. Y V

19. The method of producing soap flakes having a high degree ofporosity and easily soluble in water which comprises spraying inv fine clouds a liquid soapof a vhigh air content upon a movingl surface whereby ,the air may be readily released during the hardening of the soap, and finally disturbing the soap so that it will crumble into Hakes ofcrystalline appearance upon being removed from said surface. i

20. The method of producing soap Hakes having a high degree of porosity and easily' soluble in water. which comprises taking liq-` uid soap of any density and adding a thinning Huid thereto whereby the liquid soap may be given a desired volume of air by subsequent agitation, then applying the soap to a surface in a manner to continue the agitation andthe admixture of air with the soap but upon being spreadA upon said surface to effecta release ofthe air during a subsequent drying or hardening step, and finally removing the soapfromy said surface in the form of Hakes or like particles.

21. The method of producing soap flakes easily soluble i'n water which comprises spraying liquid soap of a high air content upon a moving surface in a substantially thin layer whereby uponv hardening of-the soap the walls thereof confining the air therein will contract and release the air, and finally `removing the hardened air-freed. soap from said surface for disintegration into separate flakes or particles.

22. The process of manufacturing soap in part-icle form` having voids therem which comprises adding water to ordinary soap stock of commercial manufacture to make it a free flowing liquid soap solution and heating the same to maintain it at a certain temperature whereby the soap solutionwill be kept ifi a good free flowing state, effecting the void formation and the solidification of the soa n into permanent form retaining condition y inflating the soap to increase. the volume thereof and removing the moisture by subjecting it to currents of heated drying gas until the moisture content is reduced to a desired value, and collecting the soap sub? stantiall at the end of the heat `treatment in the orm of solidified particles having voids therein.

23. The process of manufacturing soap in substantially dry void-containing particle form which comprises adding water thereto to make it afree flowing liquid soap solution capable of inflation to increase the volume thereof and promote the formation of voids therein, evaporating the moisture from the soap solution by inflating the sameland subjecting it to currents of heated drying gas- `while evaporation takes place until the moisture content is reduced to a desired value, and collecting the soap substantially at the end of the heat treatment in the form of solidified void-containing particles.

24. The process of producing a reasonably finely divided soap in characteristically dry porous component particles of void formation quickly soluble in a washin fluid which comprises adding water to or inary soap stock of commercial manufact-ure to make it a free flowing liquid soap stock capable of being readily sprayed in a finely divlded condition, then spraying said soap in a finely divided condition and effecting formation of said characteristically dry porous component particles by inflatin the same to promote void formation and so idication thereof into permanent form-retainii condition by a heat treatment involving brlnging said soa after sprayed into contact with/ currents of eated as until the formation of said dry porous mflated particles takes place and the solidification thereof into notably porous structures having voids therein is effected.

25. The process of producing a soap product of characteristically dry porous component particles quickly soluble in a Washing fluid which comprises adding water to ordinary soap stock of commerclal manufacture to make it a free flowing liquid stock capable of being readily sprayed, then Spraying the liquid soap and thereafter allowing it to move into Contact with currents of heated gas, and effecting solidification into fpermanent form by said heat treatment, sai heat treatment continuing until the formation and soli/dificatlon are complete and said particles are y produced in a porous condition substantially drythroughout. v l

26. The process of producing a reasonably vfinely divided soap in characteristically porousy component void containing particles which comprises adding waterto ordinary soap stock of commercial manufacture to make it a free flowing soap solution, and effecting formation and solidification of said characteristically Vvporous component voidcontaining particles b spraying said soap solution of increased liquidity and bringing it after sprayed into Contact with heated desiccating gas until the moisture content is reduced to a desired value, then lowering the temperature of the soap by bringing it into contact with cooling gas, the formation of said component void containing particles including inflating the soap, in its treatment, to effect permanent formation of said voids so that upon completion of said desiccating and cooling the soap may be'removed as component particles with voids therein.

27. The process of producing a reasonably finely divided soap in characteristically porous component void containing particles which comprises adding water to ordinary soap stock of commercial manufactureI to make it a free flowing liquid stock, and effecting formation and'solidification of said characteristically porous component void containing particles byspraying said liquid soap of increased liquidity and bringing it after sprayed into contact with currents of heated drying gas, the formation of said component void containing particles including inflating the soap, in its treatment, to effect permanent formation of said voidsso that, upon completion of said drying, the soap may be removed as component particles with voids therein.

In testimony whereof I have subscribed my name this 5th day of August, 1929.

BERTRAM WM. COLTMAN.

CERTIFICATE oF CORRECTION.

Reissue No. 18,546. 1" July 26, 1932.

I Bonnema w. coLTMAN.

\ It is hereby certified that error appears in the printed specification of the above numbered. patentl requiring correction as follows: Page 5, line 23, claim 23,\strike out the word "thereto" and insert the wordsv to ordinary soap stock of commercialv manufacture; and that the said Letters Patent should be read with this correction therein thatthe same may conform to the record of the case in the Patent Office. i

Signed and sealed this 8th dayl of November, A. D. 1932.

- MJ.v M0re, (Seal) Acting Commissioner of Patents. 

